Polytechnic Journal: Vol.7 No.

4 (2017)

INVESTIGATION OF THE EFFECTS OF NUMBER OF BLADES

ON THE PERFORMANCE OF CROSS-FLOW TURBINE USING
STAR CCM+

Saeed R. Yassen

Mechanical Eng. Department , College of Engineering ,Salahaddin University-Erbil

ABSTRACT

Virtual hydraulic turbine method has become a very powerful technique to capture minor details of
the flow which are impossible in the physical model testing and overcome the limitations of the
physical laboratory setup; therefore, the current study conducted on the virtual hydraulic turbine by
using Star ccm+ simulation code combined with CATIA V5 computer aided design software to
improve the operation of the turbine according to the analysis results to establish the optimal
number of the runner blades for the chosen turbine. The internal flow simulation results are used to
characterize the turbine performance for a different number of blades. Six different turbine runners
of 15, 20, 25, 30, 35 and 40 blades were investigated. According to current study, the most effective
number of blades noticed was 30 blades.

Keywords – Cross-flow turbine, Computational fluid dynamics, Turbine blades and Star ccm+.

INTRODUCTION

With Kurdistan electricity demand increasing, exploitation of the considerable potential of streams
or small rivers for hydro power generation in many areas, especially the rural and mountainous
areas, is an attractive prospect. However, with increased awareness of the potential adverse effects
of energy crisis and the underlying need for cost-effectiveness, decisions on the scale of new
developments are more difficult to make, taken into consideration the relative adverse
environmental and social effects of the hydroelectric power plants, and its economic performance.
Large-scale hydroelectric power plants are already installed in Kurdistan near large rivers and dams.
Large-scale hydroelectric power plants require large dams such as the Mosul, Darbandikhan and
Dukan dams. However, it remains to harness the small-scale hydro power resources. Micro
hydroelectric power plants are usually installed in places where streams or small rivers can be
harnessed for electric power generation. All over the world, only a little portion of the available
energy in streams and small rivers is utilized for electricity generation (Barglazan, 2005). Micro
hydroelectric power plants are a solution to the power needs of remote communities. The cross-flow
turbine is proposed for micro hydroelectric power plants in this study due to its simple structure,

DOI: 10.25156/ptj.2017.7.4.45
 INVESTIGATION OF THE EFFECTS OF NUMBER …….. 2

low cost of investment (Yassen, 2014). The cross-flow turbine has modest efficiency compared to
other complicated design turbines (Kaplan and Propeller turbine). In order to improve the efficiency
of the turbine commercial CFD simulation code has been used to study the turbine operation and
determining the parameters and phenomena that affect its performance. Nowadays, CFD simulation
codes are regarded as an industry standard for this process (Carregal-Ferreira et al., 2002). The
progress in CFD simulation codes has allowed the researchers and engineers to model and obtain
three-dimensional flow field simulations in turbines. Turbomachinery designers regularly use flow
field simulation for predicting performance of hydraulic reaction turbines. However, flow field
simulations for predicting the action turbine performance with free surface flow conditions have
slowly emerged due to the complex nature of this physic phenomenon (De Andrade et al., 2011). In
1903, the simple cross-flow turbine was invented (Kaniecki & Steller, 2003). Since then, the design
of the cross-flow turbine has been developed by changing the geometric parameters through various
experimental and theoretical investigations. These changes have improved the performance of the
turbine. The efficiency and performance of the turbine strongly depend on the number of blades as
the water energy is extracted from water by the blades. Therefore, selecting the optimum number of
blades is crucial to improve the performance of the turbine. Increasing or decreasing the number of
blades on a certain number of blades has an undesirable effect of reducing the efficiency. In 1988,
Khosrowpanah et al conducted an experimental investigation to select the optimum number of
blades. The experimental results revealed that the turbine with 15 blades has the highest efficiency
within the range of 10 to 20 blades (Khosrowpanah, Fiuzat, & Abertson, 1988). In 1992, Olgun and
Ulku conducted an experimental investigation to study the effect of the number of the runner blades
on the efficiency of the cross-flow turbine. They stated that the optimum number of blades was 28
blades within the selected 20, 24, 28 and 32 blades (Olgun & Ulku, 1992). In 1994, Desai and
Aziz’s experimental investigation revealed that increasing the number of blades from 15 to 30 has a
desirable effect of the performance of the turbine (Desai & Aziz, 1994). In 1996, the experimental
investigation by Costa Pereira and Borges unusually and surprisingly revealed that the number of
blades has an unclear effect on the performance of the cross-flow turbine (Costa Pereira & Borges,
1996). It must be noted from the above studies that the number of blades has an indeterminate effect
on the turbine performance. Khosrowpanah et al stated that the optimum number of blades was 15,
while Desai and Aziz stated that increasing the number of blades from 15 to 30 has a desirable
effect of the performance of the turbine. Therefore, in this paper virtual methods were utilized to
resolve this inconsistency through three-dimensional flow visualizations to determine the optimum
number of blades. The geometrical parameters’ details of the tested cross-flow turbines used in the
current investigation are as follows; the diameter ratio is 0.67, the runner outer diameter is 0.3 m,
the diameter of the shaft is 0.04 m, the angle of attack is 16o m, the nozzle entry arc is 90o, the blade
radius of curvature is 0.047 and six different turbine runners of 15, 20, 25, 30, 35 and 40 blades
were designed using CATIA V5 and modelled by Star ccm+ simulation code.

FUNDAMENTAL EQUATIONS OF FLUID MECHANICS

The fundamental equations that describe fluid flow behavior are the Navier-Stokes equations. The

integral form of Navier-Stokes equations is as follows.
d  u dn  0 …
t 

s j j

(1)   ui uj 

u d  u u dn   pdn    dn  s d …
t     x  j  ui


 x
i

 

s j i j s j s eff

 j i 

(2)
Where  is the density, p is the pressure,  is the volume, ui is the velocity component, dn j are

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 INVESTIGATION OF THE EFFECTS OF NUMBER …….. 3

elemental surface area, eff is the effective coefficient of viscosity and sui is a momentum source
term.

THE K  TURBULENCE MODEL

The most successful and widely employed turbulence model during the last two decades is the k 
turbulence model. It is a two equations model that includes two extra transport equations that
represent the turbulent behavior of the flow. Even if this turbulence model has some drawbacks, it is
still an industry standard and can successfully be applied in advance two-phase CFD simulation
work, as the current one (Gebrewold, 2010). The k  model is a semi-empirical model based on
model transport equations for the turbulence kinetic energy ( k ) and its dissipation rate (  ). The
model transport equation for turbulence kinetic energy is derived from the exact equation, while the
model transport equation for dissipation rate has been obtained using physical reasoning and bears
little resemblance to its mathematically exact counterpart. The turbulence kinetic energy and its rate
of dissipation are obtained fromthe following transport equations (Pandey, 2010).
 
k   ku i      t  k   G  G    Y  S …
t x x   x 



k b M k

i j  k  j 

(3)
and
     t     2


  i u   




     C G  C G   C   S …
t xi xj    xj 
1
k
k 3 b 2
k 

(4)
In these equations, G k represent the generation of turbulence kinetic energy due to the mean
velocity gradients, G b is the generation of turbulence kinetic energy due to buoyancy, YM represent
the contribution of the fluctuating dilatation in compressible turbulence to the overall dissipation
rate, C1 , C2 and C3 are constants. k and  are the turbulent Prandtl numbers for turbulence
kinetic energy and dissipation rate respectively. Sk and S are user-defined source terms.

The turbulent viscosity, ( t ) is computed by combining k and  as follows

k
  2

C …

t
(5)
Where C is a constant.

STAGES OF A CFD SIMULATION

The hydraulic turbines have been influenced by the development of Computational Fluid Dynamics
(CFD) techniques during these years. CFD is an essential procedure for designing and improving
the hydraulic turbines (Čarija & Mrša, 2003; Nuantong & Taechajedcadarungsri, 2009). The fluid
flow visualization enables the engineers and researchers to improve the hydrodynamic behavior of
the turbines in order to get more and more efficient hydraulic turbines for the power generation.
Emerging CFD simulation codes specially designed to evaluate the efficiency of the turbine have
made design of turbine a step ahead. CFD simulation method has become a very powerful technique
to capture minor details of the flow which are not possible in the physical model testing. It has
overcome the limitations of the physical laboratory setup. In additional, CFD methods provide a
safe test environment with reducing the time and cost required to undertake complete tests.
Moreover, the continuously progress in the development of CFD simulation codes and computing
power has led to transfer more weight and investment to CFD simulation methods.
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In the current study, Commercial simulation code Star ccm+ was used to perform the Reynolds-
Averaged Navier-Stokes (RANS) CFD calculations with a two-phase flow model, water-air free
surface model. A complete Star ccm+ simulation consists of three main stages. These stages are
Star ccm+ Modelling and Meshing, Star ccm+ Solution and Star ccm+ Results. The accuracy and
quick simulation of CFD simulation codes are strongly influenced by these three main stages.

Star ccm+ Modelling and Meshing

This stage is the interface through which the user defines the simulation. It includes identification of
the flow region of interest, representation of the geometric region, specification of the grid, the
boundary conditions and the physical models. Proper simplifications of the region of interest play a
key role in the accuracy of CFD simulation results and the computer time required for a solution.
The modelling and meshing stage involves the following:
 Geometric Definition: Star ccm+ 3D-CAD Model allows the user to create the geometry from
scratch or importing the geometry from computer aided design (CAD) software like CATIA,
Solidworks, AutoCAD and much more. CAD geometry for turbine was generated in CATIA
V5 as shown in figure 1.

Figure 1. CAD model of cross-flow turbine.

CATIA at its core is a full functioned CAD solid modelling tool that is widely used in industry
(Aurel, Ispas, & Zapciu, 2011). Once the geometry was complete, the preparation of the
computational domain for the mesh generation started. While defining the computational domain
appropriate simplifications of the geometry are required. Features that do not affect the flow
behavior in an appreciable manner or are too small to be resolved are not included in the
computational domain as shown in figure 2. The cross-flow turbine was created in the simplest way
so as to get a better mesh distribution as the quality of the mesh depends on the complexity of the
geometry.

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 INVESTIGATION OF THE EFFECTS OF NUMBER …….. 5

Inlet

Blade

Nozzle
Outlet

Figure 2. 3D Cross-flow turbine full assembly - Computational domain.

 Grid Definition: Star ccm+ Mesh allows the user to discretize the computational domain into
numerous small cells as shown in figure 3. The CFD finite volume numerical simulation results
accuracy strongly depends on the quality of the mesh. The solution mesh dependency was
tested by starting with a coarse mesh. The number of the elements was increased until the CFD
simulation results were no longer significantly affected by any further.

Figure 3. 3D Cross-flow turbine full assembly - volume mesh plane section.

 Fluid Properties Definition: Two-phase flow model, water-air free surface model, was used.
Each fluid domain or surface has its own distinct property. The properties of the fluid used in
the computational domain are defined at this stage.
 Boundary Conditions Definition: Physical models within the Star ccm+ software was activated
to simulate flow physics pertaining to the turbine. Appropriate boundary conditions were
applied to define regions of inflow, outflow, walls and other important features.

Star ccm+ Solution

Once the flow region of interest definition is completed. It is submitted to the solver for
computation of a solution. The solution stage is used to set the numerical factors, compute and
monitor the solution. The governing equations are solved by using a numeric method to find values
for all the variables in each cell of the user-defined mesh. This stage usually uses one of three
distinct ways of calculating the solutions, namely, the finite difference method, finite element
method and the finite volume method. Star ccm+ uses the finite volume method technique which is
the most popular technique for discretizing the governing equations (Cao, 2011). The governing
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 INVESTIGATION OF THE EFFECTS OF NUMBER …….. 6

conservation equations are integrated over each one of the control volumes (cells). The results
obtained in solver step are fed into the post-processor for examination.

Star ccm+ Results

This stage is performed in order to extract the desired information from the computed flow field.
Star ccm+ Post-processor was used to represent and plot the flow variables in vectors and contours
to display the trends of velocity, pressure and other properties of the flow.

RESULTS AND DISCUSSION

Star ccm+ Post-processor played an important role in envisaging the flow field of the inner flow for
the turbine as shown in figures 4 to 7. Three-dimensional velocity streamlines of the internal flow
of the entire turbine is shown in figures 4 (a) to (f). The path of water is not uniform and the
velocity streamlines indicate that only a portion of the rotor takes part in the flow process. It is also
evident from the figures that the nozzle is responsible for directing the internal flow of water. The
flow pattern is constricted along the nozzle inlet passage leading to acceleration of the fluid pace.
The runner core flow gains momentum as it is subjected to cross flow currents coming from the
runner blade passage of the first stage before entering the second stage. Figures 4 (a) to (f) illustrate
that the Number of blades has a clear influence on the flow exit angle. The flow exit angle increases
with increasing the number of blades. Furthermore, as a result of a considerable reduction in the
passages width between the blades due to the increase in the number of blades the entry velocity of
the water to the first and second stage of the runner increased as shown in figure 5 (f).
The complex nature of the flow in the entire turbine is revealed in figures 5 (a) to (f), which shows
the velocity vectors of in the turbine. Changing the number of blades can change the flow structure
in the runner. Regions of intense flow activities are shown in various parts of the runner. As an
example, it is interesting to note that as the number of blades increases, water splatter from the inner
and outer of the runner also increases. This splatter, which is in the form of very small water
droplets of fine diameter, concentrates close to the runner rim. The water eventually loses
momentum and descends to lower part of the turbine casing where they mix the rest of the water
leaving the turbine. Splatters and vortices most certainly cause lower power output and lower
efficiency as well as undesirable vibration and noise.

Figures 6 (a) to (f) shows the result of the simulation of the water volume fraction. The two-phase
flow, which is well-defined by the interface between the air and water. These figures revealed that
the impingement of the flow leaving the upper raw of blades on the runner shaft increases with
increasing the number of blades.
Figures 7 (a) to (f) show the pressure distribution in both the nozzle and the runner. As almost
uniform high pressure can be seen in the nozzle in all cases. Regions in the runner where the
pressure is almost atmospheric indicate regions of no flow. Such regions are empty of water and
these are indicated by atmospheric pressure.

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 INVESTIGATION OF THE EFFECTS OF NUMBER …….. 7

(a) Number of Blades (15) (b) Number of Blades (20)

(c) Number of Blades (25) (d) Number of Blades (30)

(e) Number of Blades (35) (f) Number of Blades (40)

Figure 4. (a) to (f) 3D velocity distribution.
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 INVESTIGATION OF THE EFFECTS OF NUMBER …….. 8

(a) Number of Blades (15) (b) Number of Blades (20)

(c) Number of Blades (25) (d) Number of Blades (30)

(e) Number of Blades (35) (f) Number of Blades (40)

Figure 5. (a) to (f) Velocity Vector plot (midplane face).
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 INVESTIGATION OF THE EFFECTS OF NUMBER …….. 9

(a) Number of Blades (15) (b) Number of Blades (20)

(c) Number of Blades (25) (d) Number of Blades (30)

(e) Number of Blades (35) (f) Number of Blades (40)

Figure 6. (a) to (f) Volume fraction contours (midplane face).
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 INVESTIGATION OF THE EFFECTS OF NUMBER …….. 10

(a) Number of Blades (15) (b) Number of Blades (20)

(c) Number of Blades (25) (d) Number of Blades (30)

(e) Number of Blades (35) (f) Number of Blades (40)

Figure 7. (a) to (f) Pressure contours (midplane face).
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 INVESTIGATION OF THE EFFECTS OF NUMBER …….. 11

Figure 8 represents an evaluation of the performance of the different number of blades used. The
blades are the most important piece in turbine as the water energy is extracted from water by the
blades. According to the simulation results, an increase in the number of blades from 15 to 30
enhanced the efficiency of the turbine. A further increase in the number of runner blades from 30 to
40 tends to cause a reduction in the efficiency. Further increase the number of blades increases the
unwanted activities such as the water impingement on the tip of blades and the shaft (Figures 5 (a)
to (f)). It is rather interesting to note that the hydrodynamics flow characteristics within the turbine
strongly influenced by the blade prediction for the water jet which in turn influenced by the number
of blades. A comparison of the water velocity vectors of figures 5 (a) to (f) reveals that velocity
vectors are rather uniform for a runner with 30 blades with minimum unwanted flow activities at the
runner center and rim (Figure 5 (d)). According to this, the most effective number of runner blades
noticed was 30 where the turbine’s efficiency was 67.231 per cent. Therefore, the optimum number
of runner blades can be considered to be 30, which is in agreement with Desai and Aziz (1994)
conclusion. Their results showed that the efficiency of the cross-flow turbine increased by
increasing the number of runner blades from 15 to 30 (Desai & Aziz, 1994).

80
70
60
Efficiency (η)

50
40
30
20
10
0
15 20 25 30 35 40
Blade number (nb)

Figure 8. The turbine efficiency.

CONCLUSIONS

In this work Star ccm+ simulation code combined with computer aided design software (CAD),
CATIA V5, have been used to characterize the turbine performance for a different number of
blades. Six different turbine runners of 15, 20, 25, 30, 35 and 40 blades were designed using
CATIA V5 and modelled by Star ccm+ simulation code. The three-dimensional transport structure
of the flow was effectively analyzed for a geometry that represented extreme complexity inside a
hydraulic turbine section with working conditions resembling the normal operation of the machine.
Despite the redundancy of hydrodynamics theory, the code was highly responsive to the considered
variables and proved to be efficient in providing solutions for actual working conditions. The main
points that were concluded from this work are outlined below:
 The prediction results revealed fundamental and interesting details of the structure of the flow
in the runner of the cross-flow turbine by using the different number of blades. Such details
revelations are not possible with conventional flow visualization or other techniques.

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 INVESTIGATION OF THE EFFECTS OF NUMBER …….. 12

 Water flows only through part of the runner and fills part of the total number of blades at one
particular time.

 The possibility of the flow impingement on the runner shaft increases with runners of a higher
number of blades.
 Water splatter increases with higher blades’ number.
 The selection of an appropriate number of blades in the runner almost eliminated the unwanted
phenomena which in turn should improve noise and vibration in real turbines.

ACKNOWLEDGMENT

The author would like to express his deepest thanks to Dr. Sami H. Nasser, Principle lecturer at
school of engineering and technology, University of Hertfordshire for his help and support.

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